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Jam l, 1963
s. B. sHus'rAcK
APPARATUS FOR CATALYTIQ TREATMENT OF INTERNAL
COMBUSTION ENGINE EXHAUST GASES
Filed oct. s, leso
3,071,449
WN.
9,VQww
STANLEY B. SHUSTÄC/f,
/NVE/V TOR.
5”
¿W6
PATENTAGENV.'
rates arent 0
C6
l
3,il7l,449
Patented Jan. 1, 1953
2
3,071,449
A single pyrolytic chamber is all that is required to
v
APPARATUS FOR tCATALYTIC TREATMENT ÜF
thermally decompose unburned hydrocarbons for a single
EÁÈERNAL
CÜMBUSTIÜN ENGINE EXHAUST
ES
or dual exhaust system, respectively, also the acetylenic,
olelinic and lower aldehyde fractions (which contain the
Stanley B. Shiistack, 1753i) Ventura Blvd., Encino, Calif.
Filed Oct. 3, 196%, Ser. No. 59,923
carbon atom) emitted from an internal combustion en
gine. This is because the gases discharged contain from
3.6% to approximately 1.5% carbon monoxide, all of
which at elevated temperatures in the pyrolytic chamber
2 Claims. (Ci. 23-288)
This invention relates to a means and method for puri
fying the exhaust gases of an internal combustion engine
and the like and more particularly to a new and improved
muñier construction intercepting the exhaust line of an
is reducible to carbon and hydrogen and partly to carbon
dioxide (CO2). The gases are pyrolyzed or burned after
they have traversed a comparatively short path over the
internal combustion engine for pyrocatalytically treating
burning catalytic bed of this invention. The unburned
unburned hydrocarbons and other fractions in the exhaust
hydrocarbons now emitted to the atmosphere in the oper
gases to render the noxious gases harmless.
ation of motor vehicles not having effective afterburners
15
In the past, extensive efforts have been made to render
are the main cause of air pollution detrimental to life
noxious exhaust gases harmless and many methods and
and property in the atmospheric condition known as
expedients have been proposed, including the use of
smog.
catalysts, but due to various defects in the prior proposals,
This invention -provides an improved pyrocatalytic ap
none of them has shown any promise of successful
paratus which, when attached to the exhaust manifold of
20
utilization.
an internal combustion engine, and the like, prevents the
in general, the present invention provides an improved
partly burned and unburned hydrocarbon exhaust gases
method and apparatus for using a catalyst to accelerate
from polluting the atmosphere, because the carbon atom
combustion and thermal decomposition of such unburned
in the presence of a burning catalyst is separated from the
hydrocarbons and other exhaust gas fractions, down to
hydrogen atom and the carbon monoxide molecule, set
elemental carbon and hydrogen.
ting free the hydrogen and oxygen atoms which react to
This invention further provides a new and improved
form water vapor. The carbon is expelled in harmless
catalyst bed comprising a plurality of gravel-sized pellets
form while the hydrogen is likewise expelled in either
having highly heat-tolerant cores coated with a relatively
free form or combined with oxygen as water.
thin layer of a catalytic metal oxide or a mixture of
1t is therefore an object of this invention to provide
several selected metal oxides and a new and improved
a new and improved means and method for purifying
means and method for recoating the pellets with like
the exhaust gases of internal combustion engines, and
catalytic material for greater economy, efficiency and
the like, so as to thermally decompose known irritant
practical maintenance of the device.
The results of typical analyses of automobile exhaust
unburned hydrocarbons and other fractions in the exhaust
gases to appreciably reduce the causes of smog.
More specifically, it is an object of this invention to
provide a new and improved means and method which
utilizes a catalyst and a means for igniting the catalyst to
gases indicate that any exhaust device, to be commercially
successful, must provide a simple and inexpensive method
for combustion and thermal decomposition of exhaust
gases into elemental carbon, hydrogen and oxygen. For
successful operation, the noxious components of the auto
mobile exhaust gases must be reduced or decomposed into
a harmless state.
The following chart sets forth the results of a typical
analysis of automobile exhaust gases and their noxious
components in the percentages evolved at various oper
ating conditions as indicated.
The figures as shown in
a temperature suitable for decomposing the noxious gases.
Another object of this invention is to provide `a cata
lyst bed which provides increased surface areas exposed
to »the gases and is economically produced and replaced
or regenerated for improved combustion and greater
economy of operation and maintenance of the apparatus.
45
Yet another object of this invention is to provide a
new and improved means and method in which both un
the chart are fairly representative for cars performing the
burned hydrocarbons and other fractions in the exhaust
four conditions of idling, acceleration, cruising and de
gases and the crank case oil vapors are thermally decom~
coloration. The actual quantities emitted may vary con
siderably from these figures, depending'upon the condi
tion of the car that is operating and its manner of opera
tion. Hydrocarbons shown in the chart are the most
important contaminants in automobile exhaust, from the
standpoint of formation of smog:
50
posed.
A further object of -this invention is to provide a new
`and improved means and method of the character de
scribed which includes an irrproved catalyst igniting
means which is `adapted to lbe automatically operated
55 when the engine is operated and is in constant operation
for constant operational efñciency.
A still further object of this invention is to provide in
Results of a Typical Analysis of Automobile
Exhaust Gases
dicator means combined with the apparatus for remotely
Idling
Accel-
Cruising
eration
indicating the condition within the apparatus so as to
Decsl
eration
60 provide visual, or other, indication of eñicient operation
`and facilitate policing of smog conditions *by air pollu
Hydrocarbons
(C3-Cu)
as
Hexane, ppm ___________ _.
1, 275
410
354
5,125
or Olefinic, ppm ________ ._
825
18
64
687
Acetylenic
as
Acetylene
Oxides of Nitrogen as (NO2),
ppm ____________________ ._
8
4, 180
1,606
18
88
1,369
264
193
3.6
0.0
0. 4
1. 5
cen ______________________ __
10.0
13. 7
12. 9
6.1
Oxygen (Oz), percent ...... __
1. 4
1. 3
1.1
9. 5
Lower Aldehydes as Form
aldehyde, ppm _________ __
Carbon
Monoxide
(CO),
percent __________________ _.
Carbon Dioxide (CO2), per»
tion control authorities.
Another object of this invention is to provide La new
and improved apparatus of the character described which
65 is economical to manufacture, capable of mass produc
tion and of interchangeability of parts thereof.
An important feature of this invention is the provision
for means for recoating recoatable pellets for regenera
tion thereof for greater economy and eñiciency.
A general object of this invention is to provide a new
70
yand improved means and method of the character- de
3,071,449
3
scribed which overcomes disadvantages of prior means
and methods heretofore intended to accomplish generally
similar purposes.
These and other objects of this invention will ‘be more
apparent from the following detailed description, draw
ings `and appended claims.
In the drawings:
FIGURE 1 is a vertical, cross-sectional view, as taken
substantially through the center of the improved pyro
catalytic means of this invention;
'
FIGURE 2 is an enlarged, perspective view of a por
tion thereof; and
FIGURE 3 is an enlarged, cross-sectional view, as
taken substantially through a plurality of catalyst coated
pellets comprising the catalyst bed illustrated in FIG
URE 1.
Referring in detail to the drawings, there is shown by
way of illustration, but not of limitation, a new and im
nickel oxide, three parts of cobalt oxide and one part of a
rapid setting, cementitious adhesive material, such as
alumdum. These components are mixed in a dry state,
after which water is added. The metal oxides and
»alumdum in this fluid-suspended state is poured, sprayed
or otherwise applied to the exterior of the cores 17.
The catalyst coating 38 of approximately 1/32 of an inch
in thickness has been found to provide satisfactory service
for approximately five thousand miles of normal driving.
During driving the catalyst coating becomes partly cov
ered by carbon, especially in urban driving, after which
the coating is to be renewed or recoated approximately
ever 3000 miles. For this purpose, refilling tubes 39, two
herein shown, are affixed as to the upper portion of the
tubular wall 16 and having one or more extensions or
branches 41 for dispersing the huid-suspended mixture of
metal oxides and adhesive. Open ends 42 extending out
wardly of the tubular wall 16 are capped as by removable
proved pyrocatalytic means designed and constructed in
caps 43. To recoat the pellets 36, the caps 43 are removed
by the numeral 10.
The ‘apparatus 10 comprises a housing 11 defining a
The alumdum is a very rapid-setting adhesive which en
chamber 12 having an inlet 13 and an outlet 14 and be
recoating, the caps 43 are threadedly or otherwise secured
and the recoating fluid mixture is poured through the tubes
accordance with this invention and referred to generally 20 39 to be directed over the pellets 36 to recoat each pellet.
ing otherwise hermetically sealed from the atmosphere.
The housing 11 may lbe conveniently formed of 4a tubu~
lar wall 16 of rounded, elliptical or other configuration
and closed at its ends by end walls 17 and 18. The end
wall 17 is preferably permanently secured as by welding,
indicated at 19, or the like, and has integrally, or other
ables complete and fast recoating of each particle. After
' to the open ends 42 to reseal the chamber 12. The tubes
39 are preferably perforated so that residue mixture of
coating material may be burned off during the pyrolytic
action during operation of the apparatus 10.
It has been found that by the use of irregularly-shaped
pellets, such as 36, rather than a solid catalyst mass, the
wise, formed therewith a tubular extension forming the 30 area of catalyst exposed to the exhaust gases is greatly
outlet 14. The tubular extension or outlet 14 has a flange
21 formed integrally therewith to facilitate securement
as by fasteners 22 to an exhaust pipe 23 leading, in con
ventional manner, to the rear of the vehicle (not shown).
increased inasmuch as the gases may flow between the
inner spaces 44 between pellets. Greater economy is
afforded inasmuch as a solid mass of catalyst is com
expensive whereas the pumice cores 37 are rela
The end wall 18 is preferably removably secured to 35 paratively
tively inexpensive and the coating 38 relatively thin and
the tubular wall 16 as Aby fasteners 24, in the form of
therefore relatively inexpensive.
bolts or the like, extending through the end wall 18 and
-a flange 26 formed integrally with or secured to the tu
bular Wall 16. A tubular extension extends therefrom to
form the inlet opening 13 which is provided with a flange
27 to facilitate securement to the exhaust manifold 28,
as by fasteners 29, of the internal combustion engine and
through which exhaust gases from the engine (not shown)
are directed into the chamber 12 as indicated by the ar
rows 31.
A tubular branch 32 is preferably formed and com
municating with the inlet tubular extension 13 to which
The pellets 36 may be conveniently contained within a
perforated basket 46 having an opening 47 through which
additional pellets like 36 may be added if necessary by
removal of a similarly perforated cap indicated at 48.
The basket 46 is removably supported within the chamber
12 as by spring clips indicated at 49, the entire basket
being removable from the chamber 12 as through the open
end of the tubular wall 16 when the end wall 18 is re
V- moved.
Furthermore, the forming of the catalyst with a plu
rality of recoatable pellets 36 facilitates policing of the
a conduit 33 may Ibe conveniently secured and corr muni
device by control authorities. When the pellets 36 are
cated with the crank case oil gas Vapor outlet (not shown)
recoated, it is recommended that a servicing notation be
for communicating crank case oil vapor to the inlet 13 50 made on a sticker or the like, which when checked by a
which is carried by the exhaust gases from the exhaust
manifold 28 into the chamber 12 for a purpose which
will be hereinafter described.
control oñìcer, will indicate whether the catalyst has been
regenerated within the proper period of time or mileage
driven by the vehicle. An additional indicator means for
A catalyst bed, generally designated by the numeral 35
checking the condition of the apparatus will be herein
is supported within the chamber 12 for pyrocatalytic ac 55 after described.
tion relative to unburned hydrocarbons and other frac
In accordance with catalytic chemistry, metal oxides
tions in the exhaust gases directed into the chamber 12
readily give off electrons which facilitate the breaking
to assist in thermal decomposition thereof in a manner
of bonds of the hexane molecules, forming (C=C) double
to be herein described. As best seen in FIGURES 1 and
bonds known as soot or carbon black, plus (H2) hydrogen,
3, the catalyst bed 35 comprises a plurality of relatively 60 when the temperature thereof is raised to approximately
small irregularly-shaped pellets 36, preferably of a gravel
1100 degrees F. For this purpose the apparatus 10 is pro
size. Each pellet 36 comprises a core 37 of a porous
vided with an ignition means generally designated by the
material which tolerates high temperatures, preferably a
numeral 50 extending into the chamber 12 for igniting
pumice stone, and coated with a metal oxide catalytic
the catalytic bed 38.
agent designated by the numeral 38. It has been found 65 The igniting mea-ns 50 includes a housing 51 enclosing
that the oxides of iron, nickel and cobalt all strongly
a'n air intake chamber removably secured to the housing 11
favor the complete chemical decomposition of theun
forming the chamber 12 as by a clamp indicated at 52.
burned hydrocarbons and other fractions, particularly ni
The housing S1 includes a mixing or combustion chamber
tro oxides of the exhaust gases. The nickel oxide is more
53 extending into the chamber 12 and an air inlet 54
active than the iron oxide and cobalt oxide is the most 70
adapted to be secured for communication to an air blower
active for the decomposition of the unburned, noxious
(not shown) for forcing air into the chamber 12, the air
being indicated by the arrows 56 and entering the chamber
12 as through a- perforated plate 57. A fuel passageway
58
extends centrally through the housing 51 and communi
75
preferably includes one part of iron oxide, two parts of
gases at temperatures ranging from 950 degrees F. to
1250 degrees F.
To form the coating of metal oxides 38, a dry mixture,
3,071,449
5
cates between a fuel conduit 59 and a nozzle 60 having an
orifice directed into the mixing chamber 53, forming a
very fine spray. An igniter- 61 in the form of a spark
plug, forms a spark adjacent to the nozzle 60 for igniting
6
the battery post on a voltage regulator. The engine was
started and the afterburner assembly was activated.
The active catalytic ingredient used Was a coating of
a metal oxide mixture, as previously described, on pumice
the spray of fuel in the mixing chamber 53. A baffle 62
stones, the pellets occupying approximately one-half of
is preferably formed at the opening 63 of the mixing cham
the area within the chamber to avoid excessive back pres
ber 53 to disperse fuel.
sure on the engine. A six-volt line was connected
In operation, a fuel control valve (not shown) is en
through a breaker into a common automobile ignition
ergized during operation of the engine to supply fuel to
coil. The coil was used to supply a high voltage at the
the nozzle 60 whereas an ignition coil (not shown) sup 10 spark plug at periodic intervals determined by the speed
plies a continuous hot spark to the point of the spark
of the blcwer motor. The spark was in a sense con
plug 61 to ignite the fuel-air mixture. A flaming zone is
tinuous and was able to ignite the mixture instantly.
thereby created within the chamber 12 which immediately
In the tests, the afterburner was successful in appreci
ignites the metal oxide coating 38 of the pellets 36 which
ably reducing partly burned and unburned hydrocarbons
immediately burns the partly burned and unburned 15 during idle and deceleration stages. As an example,
noxious exhaust gases. The temperature in the chamber
during an idle run of 520 rpm. of the engine, the hy
12 is raised in excess of 1100 degrees, which in the pres
drocarbons were reduced from 1300 p.p.m. to 280 p.p.m.
ence of a catalyst, is suñîcient to thermally decompose
and during a deceleration run of 1820 r.p.m., the hydro
the noxious gases.
carbons were reduced from 7100 p.p.m. to 160 p.p.m.,
The interior of the mufñer 10 is preferably lined with 20 concluding that the p.p.m. of hydrocarbons were sub
a liner 66 of a high temperature-resistant insulating mate
stantially reduced to a safe proportion which is not irri
rial, such as a refractory tile, to retain the heat wtihin the
tant in the atmosphere at the operations which are nor
chamber 12 and prevent deterioration of the walls 16, 17
mally the highest percentage of smog producing gases,
and 18 forming the housing 11. The liner 60 is preferably
idling and decelerating (see chart of Typical Analysis of
formed of discrete sections such as a tubular section 67, 25 Autcrnobile Exhaust Gases, supra).
and end sections 68 and 69 which are preferably remov
While there is herein shown and described in this in
able for replacement in the event that breakage occurs
vent'on in what is conceived to be the most practical and
due to collision of the housing.
preferred embodiment of this invention, it is to be under
An indicator means 70 is provided and schematically
stood that alterations and modifications thereof may be
shown in FIGURE 1 for indicating the temperature with 30 made in a manner to satisfy the spirit of this invention
in the chamber 12 so as to determine whether the opera
which is intended to comprehend any and all equivalent
devifes as comprehended in the following claims.
tion is eiiicient, the indicator means forming a further
means of policing the operation of the apparatus. Indi
What is claimed as new and desired to secure by Letters
Patent is:
cator means 70 shows schematically a thermal-couple
means 71 extending within the chamber 12 and electri 35
1. An apparatus for purifying the exhaust gases of an
cally connected to a pyrometer 72 located remotely, as
internal combustion engine and the like comprising a
within the interior of the vehicle and visible to the oper
walled hou‘ing defining a chamber having an inlet at one
ator thereof. It is to be understood that the opening '73
end adapted to be connected to an exhaust manifold of
extending through the end wall 17 and its insulator 68
the engine and an outlet at an opposite end, a basket
of foraminous material supported in said chamber so as
is hermetical'y sealed to seal the chamber 12. The oper
to re-eive a flow of said exhaust gas therearound and
ating temperature within the chamber 12 is indicated on
the scale of the pyrometer 72 so as to warn the operator
therethrough, a plurality of irregularly shaped catalytic
pellets in said basket, each pellet comprising a core of
rela‘ively porous and high temperature tolerant material
45 having a relatively thin coating of a metal oxide catalytic
operation to a control officer.
Addltionally, the high temperature within the chamber
material, and each being re-coatable with metal oxide by
a liuid mixture of said metal oxide in a rapid setting
12 may be advantageously utilized to heat the interior of
the vehicle carrying the apparatus 10. For example, the
cementitious adhesive material, meansv defining a passage
way through said housing for communicating said fluid
cold water inlet may be formed as at 74 to be circulated
50
mixture through the Wall of said housing and in contact
within a portion of the hot‘s`ng 76 extending within the
if the temperature drops to an impractical point and the
catalyst requires recoating or to indicate the condition of
chamber 12 as indicated at 77 and exit through a hot
water outlet 78 for transferring heat into the interior of
the vehicle.
In actual laboratory tests, besides the results found in
with said pel'ets for selectively recoating said pellets with
said fluid mixture of metal oxide while said pellets reside
in said basket, and heating means in said chamber for
selectively heating said catalytic pellets to accelerate the
practical use on a vehicle, this invention provides a great 55 temperature thereof so as to oxidize the partially burned
gases which cause the condition known as smog in areas
and unburned hydrocarbons and other fractions of said
exhaust gases for chemical decomposition thereof, said
heating means including housing means defining a cylin
having in `ersion atmospheric conditions.
drical air intake chamber mounted on said housing and
redaction in the percentage and parts per mil'ion (p.p.m.)
so as to thermally decompose irritant and noxious exhaust
To summarize a test conducted in a laboratory on this 60 having a cylindrical combustion chamber communicating
therewith and extending inwardly of said» first chamber
invention, a prototype of the invention as herein dis
adjacent said pellets and between said inlet and outlet,
c’osed and described was conducted to one exhaust line
said air intake chamber being adapted to receive ambient
of a test engine. An accessory equipment stand was con
structed to hold a special fuel meter and pressurizing
equipment, and a secondary air meter. A special abso
lute fuel meter was designed so it could be pres'urized
to any desired level. The purpose for this was to supply
fuel to the burner housing located on top of the catalytic
chamber. (This fuel would normally be supplied from
the pressurized line to the carburetor).
Sample lines
were installed, one before and one behind the apparatus.
Temperature measuring equipment consisted of two
Ch-Al thermo-couples and a pyrometer. A blower and
coil lead wires were connected through an ammeter to
air, nozzle means within said combustion chamber
adapted to be connected to a source of raw fuel for
selectively injecting said fuel into said combustion cham
ber to be mixed with said ambient air, igniting means ex
tending into the said combustion chamber and adapted to
be connected to an electrical circuit so as to selectively
70 ignite and burn a mixture of said fuel and air, the side
walls of said combustion chamber having parts there
through communicating with said first mentioned cham
ber, said combustion chamber having an open end ad
jacent said catalytic pellets, a baiiie in said open end for
dispersing the burning mixture over said pellets, said
3,071,443
7
catalytic pellets'being. heated to a‘relatively high tem
References Cited in the‘ñle of‘this patent
perature for burning the `partially burned and unburned
hydrocarbons and other noxious fractions of said exhaust
UNITED STATES PATENTS
gas for decomposition thereof in response to combustion»
of'saidy mixture `in said combustion chamber.
2.> An apparatus as_deíined in claim 1 including second
inlet means communicating with the interior of said ñrst
chamber and adapted `to be connected to the crank case
of the internal combustion engine so as to communicate
oil vapors therefrom to induce said vapors to said first
chamber for combustion thereof by said combustion
means.
1,402,814
1,834,126
1,85 8,637
2,017,481
2,862,354
2,880,079
2,909,415
2,912,300
2,937,490
2,942,932
Wachtel ___.f ____ _>_A_`.-__ Ian. 10, 1922
Hyatt ___________ _____,_`Dec. 1, 1931
McDonald __________ __ May 17,
1932 '
Von Opel ______ -_.>__M___.. Oct. 15, ’1935
1958
1959
Houdry --.A ...... _.ß.___..’ Oct. 20, 1959
Barnhart „____A__`_ ____ _u Dec. 2,
Cornelius ..... __,_____ Mar. 31,
Cannon et al. ________ __ Nov. 10,
Calvert ___». ________ __ May 24,
Elliott ---u __________ __ June 28,
1960
1960